Brushed Metallic Paper Boxes

Brushed Metallic Paper Boxes

May 15, 2025

CASE STUDIES

Brushed Metallic Folding Carton

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Project Overview

Wynalda Packaging collaborated with IT Works, an industry-leading beauty and nutrition brand, to develop a premium secondary packaging solution for their body gel. The design was expertly crafted to replicate the sophisticated appearance of brushed metal, reflecting the luxury and quality of the product inside.

FEATURES

 

SPECIALTY COATINGS

 

METALLIC

 

DURABILITY

OUR CAPABILITIES

Structure and Material

 

We created an auto-bottom top tuck folding carton, tailored to securely hold the bottle of body gel. Constructed from 18pt MPE, the material’s shiny metallic base served as the perfect canvas for creating a high-end, brushed metal look.

 

 

 

Brushed Metal Effect

To achieve the desired “brushed metal” effect, we employed an innovative combination of two specialty coatings: reticulating varnish and dull varnish. The reticulating varnish provided a subtle texture in specific areas, creating contrast with the smoother finish of the dull varnish applied to the rest of the surface. This interplay of textures brought depth and realism to the metallic base, producing a stunning brushed metal effect that captivates attention and exudes elegance.

 

Printing

 

The box’s design was intentionally minimalistic to highlight the luxurious brushed metal finish. We applied two hits of white ink to mask the metallic sheen in the areas where the text and design elements were then printed using crisp black ink. This approach allowed the brushed metal effect to take center stage, reinforcing the product’s premium positioning.

 

 

 

 

Conclusion

 

This project merges innovative techniques and thoughtful design to create packaging that enhances brand identity and product perception. The brushed metallic folding carton for IT Works exemplifies sophistication, leaving a lasting impression on consumers while effectively communicating the product’s premium quality.

Want to explore innovative packaging solutions for your product? We are always happy to help. Speak with a packaging expert today!

 

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Rigid Drawer Boxes With Layered Windows

Rigid Drawer Boxes With Layered Windows

Mar 28, 2025

CASE STUDIES

Rigid Drawer Boxes With Layered Windows

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Overview

 

In collaboration with Cinco Design, we developed a distinctive and engaging packaging solution for VSSL, a high quality outdoor gear brand.

The packaging was designed to hold a compact critical supplies kit, with a focus on both functionality and aesthetic appeal.

The solution consists of three components: an outer slip case, a rigid tray, and a cleverly engineered paperboard insert.

FEATURES

WINDOWING

SUSTAINABILITY

DURABILITY

OUR CAPABILITIES

Outer Slip Case and Paperboard Insert

 

The outer slip case is a tuck-top folding carton with an open bottom, allowing the rigid tray to slide inside.

What makes this packaging truly stand out is the series of layered cutouts incorporated into both the slip case and the paperboard insert. The front of the sleeve has a cutout revealing the insert beneath it, which features three additional layers, each with its own cutout. This layered design creates a striking illusion of multiple sleeves encasing the box, while offering product visibility.

To achieve this effect cost-effectively and sustainably, we folded a single piece of paperboard multiple times, forming layers. The result is a design that delivers depth, dimension, and both visual and tactile intrigue, while minimizing material usage and production costs.

 

 

Both the outer sleeve and the insert are crafted from 0.018 KraftPak, chosen for its strength and eco-friendly qualities.

The material is printed using four-color process, plus two hits of white ink, and finished with a dull varnish on the printed areas. To maintain a natural, earthy aesthetic, most of the KraftPak is intentionally left unprinted.

Rigid Tray

Inside the sleeve is a rigid tray, providing the package with essential structural integrity. Constructed from 0.042 kraft chipboard, the tray aligns with the natural, sustainable theme of the overall design. It is wrapped in 80# text paper, printed using four-color process and coated with a dull varnish for consistency across the entire package.

 

 

Conclusion

This packaging solution balances innovation, aesthetics, quality, and sustainability to create a visually striking and functional package that reflects VSSL’s brand identity.

Want to explore innovative packaging solutions for your product? We are always happy to help you brainstorm ideas and troubleshoot challenges. Speak with a packaging expert today!

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Cosmetics Box Packaging

Cosmetics Box Packaging

Dec 18, 2024

CASE STUDIES

 

Cosmetics Box Packaging

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Overview

 

Farouk Systems, a company known for manufacturing high-quality professional hair care products, reached out to Wynalda Packaging for a solution to package their CHI Vibes Squad Goals Kit, consisting of three product bottles.

The goal was to create a secure, aesthetic box that would prevent the bottles from rattling and shifting during transport, ensuring a premium unboxing experience for customers.

FEATURES

SPECIALTY COATINGS

INTERNAL DIVIDERS

DURABILITY

OUR CAPABILITIES

Structure & Materials

To meet these needs, we designed a top tuck auto-bottom folding carton with a tongue lock, offering secure closure and stability.

To keep the bottles from moving inside the box, we incorporated a custom internal divider that precisely fit the dimensions of the product. This divider was integrated into the structure of the box, providing a snug fit that effectively eliminated any internal movement.

For durability and a high-quality appearance, we used 24 pt SBS paperboard.

 

 

Printing & Coating

The box was printed using four-color process, achieving a bright, colorful design that reflects the playful spirit of the CHI Vibes brand.

To enhance the visual and tactile appeal, we applied an overall dull varnish and added spot gloss to key design elements, giving the package a sophisticated, premium finish.

Results

The final packaging solution for the CHI Vibes Squad Goals Kit delivered both form and function. The custom internal divider kept the bottles securely in place, while the vivid printing and specialty finishes created an eye-catching package. All of these elements came together to provide a premium unboxing experience for Farouk’s customers.

Talk with a packaging expert to learn how we can help you can elevate your brand with unique, premium packaging.

 

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NuLeaf Custom CBD Boxes

NuLeaf Custom CBD Boxes

Oct 18, 2024

CASE STUDIES

 

NuLeaf Custom CBD Boxes

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Project Overview

 

Wynalda partnered with NuLeaf, an organic CBD and hemp product manufacturer, to provide custom CBD boxes for their oils, balms, and softgels. We developed eight different seal-end folding carton designs, all constructed from FSC®-certified 20pt SBS (FSC® C149826).

 

FEATURES

EMBOSSING

SPECIALTY COATINGS

INSIDE PRINT

OUR CAPABILITIES

Inside Dividers

To hold the various sizes of products in place, many of these box designs incorporated inside dividers. Some of the cartons were designed so that when the box is erected, the dividers are automatically erected as well. Other designs required additional folding in order to accommodate the specific shape of the product.

Color Management

Each of the eight box designs has seven different color variations, indicating the type of product that it contains. For instance, their CBD products are green, their CBN products are purple, and their CBG products are yellow. All seven of these variations use custom PMS colors, which Wynalda produces and manages to insure color consistency and color quality across runs.

 

 

Inside Print

One of the defining features of these boxes is the bright inside print. The inside of each box is printed with a solid layer of that product’s corresponding color, adding vibrancy to the packaging. This design choice enhances the unboxing experience, elevates the perceived quality of the product, and reinforces NuLeaf’s branding.

 

Finishes and Embellishments

These boxes are all finished with a soft touch coating and spot gloss to give them a premium look and feel. Embossing is added to certain design elements to make them pop and enhance the tactile appeal of the packaging.

Cost Savings

These boxes are all finished with a soft touch coating and spot gloss to give them a premium look and feel. Embossing is added to certain design elements to make them pop and enhance the tactile appeal of the packaging.

 

 

Conclusion

NuLeaf has been very happy with their packaging, and has greatly benefitted from the cost savings that Wynalda is able to provide, leading to a productive partnership.

Want to explore innovative packaging solutions for your product? We are always happy to help. Speak with a packaging expert today!

 

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Don Julio Custom Box Sleeves

Don Julio Custom Box Sleeves

Sep 10, 2024

CASE STUDIES

 

Don Julio Custom Box Sleeves

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Project Overview

 

Don Julio sought to enhance their 1942 tequila bottles for the holiday season with elegant custom box sleeves, creating a special edition look perfect for gifting. Wynalda collaborated with ADM Group to develop three distinctive sleeve designs, each bearing festive messages: “Happy Holidays,” “Congratulations,” and “Happy New Year.”

 

FEATURES

EMBOSSING

FOIL STAMPING

DURABILITY

OUR CAPABILITIES

Structure & Materials

We designed a tall, slim o-sleeve tailored to fit around the slender boxes of the tequila bottles. We selected a 24pt SUS board for its durability and premium look and feel.

Printing & Coating

The sleeves were printed using two hits of a custom brown ink, ensuring rich, consistent color. To protect the sleeves from rubbing, we applied an overall gloss coating, followed by a dull varnish. By using this combination of coatings, we were able to achieve much better rub test results, while maintaining a luxurious appearance and tactile quality.

 

 

 

Embellishments

This project incorporated some complex, yet rewarding embellishments. We used hot foil to add the text and logo to the sleeve, followed by sculpted embossing to create a striking 3D effect. The challenging aspect of this design was that the embossed elements ran across the scores of the sleeve. In order to create the desired effect without affecting the crease lines, we carefully tapered the embossing at the scores.

 

Results

The holiday sleeves transformed the Don Julio 1942 tequila bottles into exquisite, gift-ready pieces. The combination of custom ink, sophisticated coatings, gold foil, and meticulous embossing created a stunning visual impact, enhancing the premium feel of the product.

Planning a limited-edition release or seasonal gift promo? Let’s design packaging that grabs attention and leaves a lasting impression. Get in touch with us today.

 

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